Minimum gas speed in heat exchangers to avoid particulate fouling

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3948 M.S. Abd-Elhady et al. / International Journal of Heat and Mass Transfer 47 (2004) 3943–3955Fig. 4. Progress of the fouling layer over the HE tube within 9 h of operation. The foulant is spherical glass particles of diameter21 ± 16 lm. The average air speed between the HE tubes is 2.7 m/s: (a) after 1 h of operation, (b) after 1.5 h of operation, (c) after 2 h ofoperation, (d) after 2.5 h of operation, (e) after 3 h of operation, (f) after 9 h of operation.Fig. 5. Growth of the fouling layer over the HE tube within 6 h of operation. The foulant is spherical glass particles of diameter 21 ± 16lm. The average air speed between the tubes is 3.8 m/s: (a) at the beginning, (b) after 0.5 h of operation, (c) after 1 h of operation, (d)after 1.5 h of operation, (e) after 2 h of operation, (f) after 6 h of operation.corresponds to a superficial flow velocity of 10 m/s. Fig. 7shows the velocity contours in the y and x directions forthe HE shown in Fig. 1. Although the CFD calculationsshow that the flow around the middle centered tube is notperiodic, this centered tube can be regarded as a representativefor a tube in a tube bundle. It is shown that for
M.S. Abd-Elhady et al. / International Journal of Heat and Mass Transfer 47 (2004) 3943–3955 3949Fig. 6. A summary for the fouling layer circumferential growth shown in Fig. 5.the middle centered tube the flow keeps attached to thetube surface and then separates at an angle of 120° fromthe stagnation point. From the numerical results it couldalso be concluded that there is more air circulation at thefront than in the rear end of the middle centered HEtube, Fig. 7c and d. Therefore particles that stick to therear end of the HE tube are more likely to remain inposition than particles that stick to the sides of the HEtube. A particle that sticks to the side of the HE tube rollsover the HE tube if the airflow speed is above a certainlimit, and stops if it is blocked by the resting particles atthe rear end of the heat exchanger tube. Therefore foulingstarts at areas that are subjected to minimum shearingforces and then spreads due to particle transport tothe already deposited particles. Fig. 6 summarizes thecircumferential growth of the fouling layer shown in Fig.5.3.2. Limiting fouling speedThe previous set of experiments has shown that asthe flow speed in the HE increases, the thickness and thesurface area of the fouling layer deposited over the HEtube are reduced. The following experiments are done todetermine the flow speed at which fouling of the heatexchanger is prevented. The results of the experimentwill be compared to the results achieved with an analyticalmodel. The analytical model is only valid forspherical non-charged particles. The analytical model isbased on the minimum shear velocity required to roll aparticle on a flat surface. It can be applied for a cylindricaltube if the particle diameter is much smaller thanthe cylinder diameter, as is the case here. The shear flowspeed required to roll a particle deposited on a flatsurface is called the critical flow velocity and it is afunction of the particle material and size and the surfacematerial. The critical flow velocity can be calculatedwhen assuming that the hydrodynamic rolling momentdue to the drag force, F d , lift force, F L , and buoyancyforce, F b , is greater than the resting adhesion momentdue to the surface adhesion force, F a , and the force ofgravity, F g . The ratio between the hydrodynamic rollingmoment and the adhesion resting moment is defined byZhang et al. [10] as RM and equal toRM ¼¼Hydrodynamic rolling momentAdhesion resting momentF d ð1:399R aÞðF a þ F g F b F L Þd=2 ; ð1Þwhere R, d and a are the particle radius, contact diameterand the particle radius of deformation, respectively.If the RM value is greater than 1, rolling will takeplace. Abd-Elhady et al. [5] have calculated the criticalflow velocity for spherical copper particles of diametersranging from 5 to 50 lm, the results are shown in Fig. 8.The main flow stream velocity, i.e. the critical flowvelocity, required to roll a copper particle of 10 lm is10.5 m/s while for a 50 lm copper particle this velocity is4.5 m/s.Due to the comparison with the analytical modelpresented above, in the experiments only sphericalmetallic particles are used. The HE is operated at differentair flowing speeds and different particle sizes todetermine the operating speed at which fouling is preventedas function of the particles size in the flow. Theflow speed at which fouling is prevented, is investigatedfor copper particles of average diameter 10 lm with astandard deviation of 5 lm suspended in the airflow andalso for bronze particles of average diameter 55 lm witha standard deviation of 6 lm. The air temperature is 20°C and the particle concentration is 2 g/m 3 of airflow.The heat exchanger is kept running for 8 h in eachexperiment. Experimental results of the fouling experimentare plotted in Fig. 8. Fig. 8 shows that when air iscontaminated with the copper particles of averagediameter 10 lm the HE tubes fouled when the averageflow speed between the tubes was lower than 9.5 m/s, i.e.
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Minimum gas speed in heat exchangers to avoid particulate fouling

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